Icemaker system for a refrigerator

ABSTRACT

An icemaker system provided in a refrigerator is designed to reduce an amount of time required to produce ice. The refrigerator includes a refrigeration system including a number of refrigeration components and a refrigeration loop. The refrigeration loop includes an icemaker section that carries a flow of refrigerant to an ice mold portion of the icemaker system and a bypass section that isolates the icemaker system from the flow of refrigerant. A control system automatically activates the icemaker system regardless of a need for cooling. That is, upon sensing a demand for ice, the control system opens a valve to cause refrigerant to flow through the icemaker section and activates the refrigeration components to speed ice production whether or not additional cooling is required in fresh food and/or freezer compartments.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention pertains to the art of refrigerators and, moreparticularly, to an icemaker system for in a refrigerator.

2. Discussion of the Prior Art

Whether it be to ensure an adequate amount of ice for a party or keep upwith daily demand, there is always a need to decrease ice productiontime. In the art of refrigerated appliances, it is known to employ fansor other similar devices to decrease an amount of time required toproduce ice. Typically, the fan is oriented to direct air from anevaporator portion of the refrigerator across an ice mold. The flow ofair disturbs a thermal barrier that is present at the ice moldincreasing temperature transfer rates and, as a consequence, decreasingice production time.

While the above arrangements utilize fans to blow evaporator air acrossthe ice mold, other arrangements directly expose the ice mold to theevaporator. The evaporator is part of a primary refrigeration systemthat is employed to maintain temperatures in a fresh food and freezercompartment of the refrigerator. While effective, the above describedsystems typically rely on a cooling demand signal. That is, regardlessof the need for ice, the above described systems only function wheneither the fresh food or freezer compartments require cooling whichnecessitates the activation of the refrigeration system.Correspondingly, even during periods when no ice production is required,the above described systems function upon activation of therefrigeration system.

Regardless of the teachings in the prior art, there still exists a needfor a system to reduce ice production time in a refrigerator. Morespecifically, there exists a need for a system that can, upon demand,decrease ice production time regardless of a need for cooling in therefrigerator.

SUMMARY OF THE INVENTION

The present invention is directed to a refrigerator including a freshfood compartment, a freezer compartment, a refrigeration system and anicemaker. In accordance with the invention, the refrigeration systemincludes a plurality of refrigeration components which operatesynergistically to establish and maintain desired temperatures in therefrigerator. The refrigeration components include at least a preferablyvariable speed compressor, a condenser and a condenser fan. In addition,the refrigeration system includes a refrigeration loop that carries aflow of refrigerant to the plurality of refrigeration components. Therefrigerator also includes various sensors that monitor temperatureconditions within the fresh food and freezer compartments, as well as alevel of ice in, for example, an ice storage bin portion the icemaker.

In further accordance with the invention, a portion of the refrigerationloop passes through the icemaker. More specifically, the refrigerationloop includes an ice maker section that passes through an ice moldportion of the icemaker. In this manner, the flow of refrigerant passingthrough the refrigeration loop supplies additional cooling to speed theproduction of ice. In still further accordance with the invention, therefrigeration loop includes a diverter valve and an icemaker bypass. Thediverter valve is selectively closed to divert the flow of refrigerantaway from the icemaker section and into the icemaker bypass duringperiods of low or no ice demand.

In accordance with the most preferred form of the invention, therefrigerator includes a controller that is operatively coupled to eachof the refrigeration system and the icemaker. The controller, uponsensing a need for an ice production cycle, activates the refrigerationsystem regardless of a need for cooling in the fresh food and/or freezercompartments.

Additional objects, features and advantages of the present inventionwill become more readily apparent from the following detaileddescription of a preferred embodiment when taken in conjunction with thedrawings wherein like reference numerals refer to corresponding parts inthe several views.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial perspective view of a bottom-mount refrigeratorincorporating an icemaker system constructed in accordance with thepresent invention; and

FIG. 2 is a schematic representation of the icemaker coupled to arefrigeration system of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With initial reference to FIGS. 1 and 2, a refrigerator constructed inaccordance with the present invention is generally indicated at 2. Asshown, refrigerator 2 includes a cabinet shell 6 provided with an upperfresh food compartment door 10 which is adapted to close off an upperfresh food compartment 12. As known in the art, fresh food door 10 isadapted to pivot about a vertical axis defined by upper and lower hinges(not shown). Within cabinet shell 6 is also defined a freezercompartment, generally indicated at 15, which is defined by a liner 18.Although not shown, freezer compartment 15 is adapted to be closed offby means of a door. With this general construction, refrigerator 2defines a bottom mount style unit. As known in the art, the doorassociated with freezer compartment 15 can either be mounted for apivotable movement about a vertical axis similar to fresh food door 10,or mounted upon slide assemblies which permit linear shifting of thefreezer door relative to cabinet shell 6.

Mounted within freezer compartment 15 is a drawer that preferably takesthe form of a basket 40. As shown, basket 40 generally has a meshed wireconstruction. However, as will become fully evident upon reading theremainder of this description, the drawer can take various forms inaccordance with the overall invention. At this point, it is simplyimportant to note that basket 40 can be selectively shifted into and outof freezer compartment 15. Although not depicted in this figure, theremay be one or more additional baskets within freezer compartment 15 thatprovide additional storage for food items.

Also shown mounted in freezer compartment 15 is an icemaker 50. Icemaker 50 is fixed against liner 18 at brackets 53 and 54 and includes anice mold 55 and a bail arm 56. In the embodiment shown, an ice storagebin 58 is positioned below icemaker 50 so as to receive and retain aquantity of ice produced by icemaker 50 for use by a consumer(s). In amanner widely known in the art, bail arm 56 is adapted to be raised andlowered based on a level of ice present in ice storage bin 58. Actually,bail arm 56 acts as a sensor that determines when the quantity of ice inice storage bin 58 falls below a predetermined level in order to signalthe need for a new ice production cycle. At this point it should beunderstood that, while shown mounted in freezer compartment 15, icemaker50 could also be located in fresh food compartment 12 in a specialty oricemaker compartment shown schematically at 70 in FIG. 2.

Refrigerator 2 includes a control system 80 that selectively activates arefrigeration system 90 to establish and maintain a selected temperaturein fresh food compartment 12 and freezer compartment 15. Towards thatend, if a demand for cooling is sensed, such as by a fresh foodcompartment sensor 93 located in fresh food compartment 12 and/or afreezer compartment sensor 94 located in freezer compartment 15,refrigeration system 80 is activated to ensure that refrigerator 2 ismaintained at the selected temperature(s). In order to satisfy thedemand for cooling, refrigeration system 90 includes a plurality ofrefrigeration components. In accordance with the invention asrepresented best in FIG. 2, the refrigeration components include acompressor 100, a condenser 104 and a condenser fan 106 which arepreferably arranged in a mechanical zone 110 of refrigerator 2. Inaddition, arranged at or near freezer compartment 15 is an evaporator116 having an associated evaporator fan 118. The refrigerationcomponents and, more specifically, the compressor 100, condenser 104 andevaporator 116 are interconnected by a refrigeration loop 130 whichcarries a flow of refrigerant. In order to optimize the coolingcapabilities of refrigeration system 90, an expansion valve 141 isarranged in refrigeration loop 130 between evaporator 116 and condenser104.

In a manner known in the art, compressor 100 establishes or creates aflow of compressed refrigerant which is guided towards evaporator 116.Evaporator fan 118 establishes an airflow across evaporator 116 which iscooled by the compressed refrigerant. The cooled airflow passes intofreezer compartment 15 to establish and maintain the selectedtemperature therein. After passing through evaporator 116, the now warmflow of refrigerant passes into condenser 104. Condenser fan 106 createsan airflow across condenser 104 to dissipate heat carried by the flow ofrefrigerant. At this point, the refrigerant re-enters compressor 100 tostart the cycle anew.

In accordance with the invention, refrigeration loop 130 includes anicemaker section 161 that passes through icemaker 50. Preferably,icemaker section 161 extends directly adjacent to or is integrallyformed into ice mold 55. In any case, icemaker section 161 guidescompressed or cold refrigerant about ice mold 55 in order to speed theformation of ice crystals in icemaker 50. In further accordance with theinvention, refrigeration loop 130 includes an icemaker bypass section170 that selectively isolates icemaker section 161 from refrigerationloop 130. More specifically, a valve 174, operatively connected tocontrol system 80, is positioned downstream of icemaker bypass portion170 in icemaker section 161. Valve 174 is shiftable between an openposition allowing refrigerant to pass into icemaker section 161 andthrough ice mold 55 and a closed position causing all of the flow ofrefrigerant to pass through icemaker bypass section 170. With thisarrangement, refrigerant passes through icemaker section 161 only duringan ice production cycle and control system 80 can optimize the flow ofrefrigerant in refrigeration system 90. In order further optimize orprovide additional efficiency gains in refrigeration system 90, a secondexpansion valve 176 is preferably arranged between icemaker section 161and evaporator 116.

In accordance with the most preferred form of the present invention,when the quantity of ice falls below a predetermined level in icestorage bin 58, control system 80 initiates an ice production cyclewhich, regardless of a need for cooling in fresh food compartment 12 orfreezer compartment 15, activates refrigeration system 90. Onceactivated, valve 174 opens, thereby allowing the flow of refrigerant topass into icemaker section 161 and circulate about ice mold 55 toprovide additional cooling to facilitate the production of ice crystals.This additional cooling is particularly necessary if icemaker 50 islocated within fresh food compartment 12. Further enhancement in iceproduction is achieved by the inclusion of a fan 183 used to direct acooling airflow onto ice mold 55.

In accordance with one aspect of the invention, compressor 100 isconstituted by a variable speed compressor. By incorporating a variablespeed compressor into refrigeration system 90, the flow of refrigerantthrough refrigeration loop 130 can be optimized. More specifically,during periods of no ice production or no need for an ice productioncycle, compressor 100 can operate at a low speed. Likewise, duringperiods when only cooling is needed in fresh food compartment 12 orfreezer compartment 15, variable speed compressor 100 can be operated ata low speed. However, in the event that fresh food compartment 12 and/orfreezer compartment 15 require cooling and an ice production cycle isneeded, variable speed compressor 100 can be operated at a full speed toensure the optimal flow of refrigerant through refrigeration loop 130.

In accordance with another aspect of the present invention, controlsystem 80 can selectively activate a harvest heater 190 in order to slowthe formation of ice crystals in ice mold 55. That is, a consumer canselect a clear ice mode for icemaker 50 through user controls 200 whichpreferably constitute a combination input panel/display unit locatedwithin cabinet 6 or on fresh food compartment door 10. The clear icemode actually slows the production of ice, thereby allowing air trappedin the ice mold to escape forming substantially, perfectly clear icecubes.

Based on the above, it should be understood that the icemaker system ofthe present invention provides an efficient mechanism for reducing iceproduction time in a refrigerator. More specifically, the presentinvention, in addition to speeding ice production time in an icemakerprovided in a freezer compartment of the refrigerator, will fosterfaster ice production in an icemaker compartment located in a fresh foodcompartment of the refrigerator. That is, by directing refrigerantdirectly through the ice mold, the icemaker will rapidly form icecrystals despite the lower temperatures in the fresh food compartment.Therefore, while shown in connection with a bottom mount refrigerator,the icemaker system of the present invention could also be employed intop mount, side-by-side, French door or the like models.

Although described with reference to a preferred embodiment of theinvention, it should be readily understood that various changes and/ormodifications can be made to the invention without departing from thespirit thereof. For instance, although the rapid ice mode is preferably,automatically established based on the position of bail arm 56, a usercould also establish the rapid ice mode through user control 200. Thisfeature could be extremely beneficial in connection with a party orother gathering when the user knows that an abundance of ice will beneeded in a relatively short period of time. In general, the inventionis only intended to be limited by the scope of the following claims.

1. A refrigerator comprising: a cabinet; a fresh food compartmentdefined within the cabinet; a freezer compartment defined within thecabinet; an icemaker arranged in one of the fresh food and freezercompartments; a refrigeration system for cooling the fresh food andfreezer compartments, said refrigeration system having a plurality ofrefrigeration components, including at least a variable speedcompressor, a sole evaporator and a condenser, interconnected through arefrigeration loop that carries a flow of refrigerant to the pluralityof refrigeration components, said refrigeration loop including anicemaker section extending to the icemaker; a temperature sensorarranged in one of the fresh food and freezer compartments, saidtemperature sensor providing a signal to activate the refrigerationsystem upon detecting a need for cooling; an icemaker bypass connectedto the refrigeration loop, said icemaker bypass selectively divertingrefrigerant so as to isolate the portion of the refrigeration loopextending to the icemaker; an ice storage bin for retaining a quantityof ice; a sensor for sensing an amount of ice in the ice storage bin,said sensor triggering an ice production cycle if the amount of ice inthe ice storage bin falls below a predetermined level; a valve arrangedin the portion of the refrigeration loop passing through the icemaker,said valve directing refrigerant to one of the portion of therefrigeration loop extending to the icemaker and the icemaker bypass; aharvest heater arranged in the icemaker, said harvest heater beingselectively activated to establish a clear ice making operation; and acontrol system operatively coupled to each of the refrigeration systemand the icemaker, wherein upon sensing a need for an ice productioncycle, said control system activates the refrigeration system regardlessof a need for cooling in the fresh food or freezer compartments.
 2. Arefrigerator comprising: a cabinet; a fresh food compartment definedwithin the cabinet; a freezer compartment defined within the cabinet; anicemaker arranged in one of the fresh food and freezer compartments; arefrigeration system for cooling the fresh food and freezer compartmentsand the icemaker, the refrigeration system including a refrigerationloop having a compartment section that carries a flow of refrigerant tothe fresh food and freezer compartments and an icemaker section thatcarries a flow of refrigerant to the icemaker, with the icemaker sectionbeing downstream of the compartment section; a temperature sensorarranged in one of the fresh food and freezer compartments, saidtemperature sensor providing a signal to activate the refrigerationsystem upon detecting a need for cooling; an ice storage bin forretaining a quantity of ice produced by the icemaker; a sensor forsensing an amount of ice in the ice storage bin, said sensor triggeringan ice production cycle if the amount of ice in the ice storage binfalls below a predetermined level; and a control system operativelycoupled to each of the refrigeration system and the icemaker wherein,upon sensing a need for an ice production cycle, said control systemactivates the refrigeration system regardless of a need for cooling inthe fresh food or freezer compartments.
 3. The refrigerator according toclaim 2, wherein the refrigeration system includes a variable speedcompressor, said control system operating the variable speed compressorso as to optimize operation of the ice maker.
 4. The refrigeratoraccording to claim 2, wherein the icemaker includes an ice mold, saidicemaker section of the refrigeration loop being integrally formed withthe ice mold.
 5. The refrigerator according to claim 2, furthercomprising: an icemaker compartment within which the icemaker ispositioned.
 6. The refrigerator according to claim 2, furthercomprising: a fan for directing a cooling airflow across the icemaker,said fan being operated by the control system upon sensing a need forice production.
 7. The refrigerator according to claim 2, furthercomprising: a harvest heater, said control system being operable in aclear ice mode wherein the harvest heater is activated to slow aformation of ice cubes.
 8. The refrigerator according to claim 2,wherein the refrigeration loop further includes an icemaker bypass, saidicemaker bypass selectively diverting the flow of refrigerant away fromthe icemaker.
 9. The refrigerator according to claim 8, furthercomprising: a valve arranged in the icemaker section of therefrigeration loop, said valve controlling a flow of refrigerant to theicemaker section.